Abstract:

A method for producing printed products with an arrangement including at
least one printing press to produce book blocks, at least one conveying
device to convey the book blocks, at least one processing device to
provide each respective book block with a respective cover, and a control
unit to control the production of the book blocks. The method includes
producing each respective cover in advance of each respective book block
production, supplying each cover to at least one storage unit, and
following the supplying of each cover to the storage unit, triggering at
least one printing press by the control unit to produce the respective
book block on the at least one printing press.

Claims:

1. A method for producing printed products with an arrangement including
at least one printing press to produce book blocks, at least one
conveying device to convey the book blocks, at least one processing
device to provide each respective book block with a respective cover, and
a control unit to control the production of the book blocks, the method
comprising:producing each respective cover in advance of each respective
book block production;supplying each cover to at least one storage unit;
andfollowing the supplying of each cover to the storage unit, triggering
at least one printing press by the control unit to produce the respective
book block on the at least one printing press.

2. The method according to claim 1, further comprising storing each cover
individually in the at least one storage unit.

3. The method according to claim 1, further comprising depositing each
respective cover in the at least one storage unit; and identifying the
respective cover during the depositing.

4. The method according to claim 3, wherein the triggering comprises
initiating the producing of each respective book block immediately after
identifying the respective cover.

5. The method according to claim 3, further comprising selecting, with the
control unit, one of the identified covers, and initiating the producing
of the respective book block based on the selecting.

6. The method according to claim 1, further comprising respectively
depositing each respective cover in a compartment of the at least one
storage unit.

7. The method according to claim 1, further comprising after initiating
the producing of each respective book block, controlling the conveying
device to supply the respective book block to the processing device prior
to removing the respective cover from the storage unit.

8. The method according to claim 1, wherein the producing each respective
cover in advance of each respective book block production includes at
least one of producing the book blocks internally by the arrangement
itself or producing the book blocks external to the arrangement by at
least one cover production device to produce the covers.

9. The method according to claim 1, wherein the supplying includes
supplying the respective cover to the at least one storage unit with aid
of a feeder.

10. The method according to claim 1, further comprising transporting the
covers with aid of at least one conveying device from a cover production
device that produces the covers to the storage unit.

11. The method according to claim 1, further comprising using the book
blocks and the covers to produce at least one of a perfect-bound
softcover, a perfect-bound hardcover, or a stitched printed product.

12. An arrangement for producing printed products, comprising:at least one
printing press to produce book blocks;at least one storage unit, wherein
at least one cover is supplied to the storage unit;a control unit
responsive to the supplying of each respective cover to the at least one
storage unit to trigger production of the book blocks on at least one of
the printing presses once the supplying is detected;at least one
processing device; andat least one conveying device to convey each cover
from the at least one storage unit to the at least one processing device,
wherein each book block is furnished with the respective cover in the
processing device.

13. The arrangement according to claim 12, wherein a device to identify
each cover is assigned to the at least one storage unit.

14. The arrangement according to claim 12, wherein the conveying devices
aids in supplying the book blocks from the at least one printing press to
the at least one processing device.

15. The arrangement according to claim 12, wherein the conveying device
further comprises at least one location to takeover each book block and
at least one discharge location to discharge each book block.

16. The arrangement according to claim 12, further including at least one
device to produce each cover.

17. The arrangement according to claim 12, wherein the arrangement is
adapted to receive covers supplied from an external location.

18. The arrangement according to claim 12, further comprising a feeder to
respectively supply covers to the at least one storage unit.

19. The arrangement according to claim 13, further comprising a feeder to
respectively supply covers to the at least one storage unit, wherein the
device to identify each cover is arranged on the feeder.

20. The arrangement according to claim 12, wherein the at least one
storage unit comprises a plurality of storage spaces for the covers,
wherein the control unit is operative to request at any time each cover
from any one of the storage spaces to be supplied to the at least one
processing device.

21. The arrangement according to claim 12, wherein the at least one
printing press comprises a digital printing press.

22. The arrangement according to claim 12, wherein the at least one
storage unit comprises a storage wheel including a plurality of
compartments which are respectively suppliable with each respective
cover.

23. The arrangement according to claim 12, wherein the storage unit is
arranged on or directly in front of the processing device.

Description:

CROSS REFERENCE TO RELATED APPLICATION

[0001]This application claims the priority of European Patent Application
No. 08405266.1, filed on Oct. 23, 2008, the subject matter of which is
incorporated herein by reference.

FIELD

[0002]An embodiment of the invention relates to a method for producing
printed products with the aid of an arrangement including a control unit,
at least one printing press for producing book blocks, at least one
conveying device for conveying the book blocks and at least one further
processing device in which respectively one book block is provided with a
cover.

[0003]Various printing methods and binding methods are known for producing
printed products in the form of books, brochures, magazines and catalogs,
wherein very different types of paper, different formats and different
finishing processes are used. A high quality is generally expected for
the printed products, even for extremely small and digitally produced
editions. Furthermore required is a highly flexible method, which makes
it possible to produce editions ranging from very large to very small
editions, right down to a single printed product. In particular the
digital printing technique has proven itself in that case since this
technology makes it possible to print a complete product in a single
sequence.

[0004]It is furthermore known that the individual steps for producing a
book can be realized successively (inline) and can also be interlinked.
However, there is a problem in particular when producing covers for
softcover books or hardcover books in which the covers must generally be
produced ahead of time since these processes, as a rule, are less
suitable for a networked operation. For example, separating devices, such
as silicon oils, are used for producing covers, wherein these oils must
vaporize prior to the laminating process, thereby requiring a specific
lead processing time.

[0005]A method is disclosed in co-owned European patent document EP
1288015 A1, for which printed sheets are gathered in a collating or
gathering device to be formed into book blocks that are subsequently
supplied to a perfect binder. The book block spines are then processed
mechanically in the perfect binder and are provided with adhesive as well
as with a cover.

[0006]Co-owned European patent document EP 1880863 A1 furthermore
discloses a method for which the covers are supplied to a storage unit,
located along the path to the processing machine. These book blocks are
respectively provided with identifying markings. Once a book block has
been identified, the control unit requests the associated cover and
supplies this cover to the processing machine.

[0007]According to International Patent Application publication WO
2006/020501 A2, either a book block or a cover is alternately produced
ahead of time in a first printing press. Once the printing is completed
and a corresponding quality control realized, the first printing press
transmits a signal to the control unit which then triggers the printing
of the associated book cover or the book block in a second printing
press. If the cover is produced ahead of time, it is moved from the first
printing press initially to an intermediate storage unit. Once the
production of the associated book block is completed, the pre-produced
cover is withdrawn from the intermediate storage unit and transported to
downstream arranged binding station where it is combined with the book
block to form a printed product.

[0008]However, if a malfunction occurs during the further travel of the
cover along the path and after the signal has been transmitted by the
first printing press, the operation already in progress for printing the
book block can no longer be stopped. In that case, the book block must
either be sent to an intermediate storage until the associated cover is
produced or it must be removed again from the process.

[0009]When using digital printing presses for successively producing
printed products, however, the process of reintroducing previously
removed book blocks into the binding process is very involved. If the
intermediate storage is not sufficient for the buffering, then the second
printing press must also be stopped until the malfunction has been
corrected.

SUMMARY

[0010]An embodiment of the present invention provides a method of the
aforementioned type which permits a more economic production of even the
smallest editions of printed products, up to a single product. The
production of the covers may be efficient and automated, if possible,
wherein it may also be possible to automatically control the orders and
to monitor the process.

[0011]The above and other objects are accomplished according to one aspect
of the invention, wherein there is provided a method for producing
printed products with an arrangement including at least one printing
press to produce book blocks, at least one conveying device to convey the
book blocks, at least one processing device to provide each respective
book block with a respective cover, and a control unit to control the
production of the book blocks, the method comprising: producing each
respective cover in advance of each respective book block production;
supplying each cover to at least one storage unit; following the
supplying of each cover to the storage unit, triggering at least one
printing press by the control unit to produce the respective book block
on the at least one printing press.

[0012]According to another aspect of the invention, there is provided an
arrangement for producing printed products, comprising: at least one
printing press to produce book blocks; at least one storage unit, wherein
at least one cover is supplied to the storage unit; a control unit
responsive to the supplying of each respective cover to the at least one
storage unit to trigger production of the book blocks on at least one of
the printing presses once the supplying is detected; at least one
processing device; and at least one conveying device to convey each cover
from the at least one storage unit to the at least one processing device,
wherein each book block is furnished with the respective cover in the
processing device.

[0013]Thus, in accordance with the subject matter of the application, the
covers may be produced ahead of time, meaning before the book blocks are
produced, and may then be supplied to a storage unit. As a result of the
cover being supplied to the storage unit, the control unit then triggers
the production of a book block in at least one printing press. If
malfunctions occur along the path for conveying the cover from the cover
printing press to the storage unit, these malfunctions do not affect the
production of the associated book block because a command for producing
the book block is triggered only if the cover has arrived at the storage
unit. In this way, the production process becomes more resistant to
malfunctions and can be monitored easier.

[0014]For this operation, the covers may be deposited individually in the
at least one storage unit and may be identified while they are being
deposited. The arrangement consequently need not have knowledge of the
covers during the production. Rather, the covers may also be produced
ahead of time in an external printing operation and may then be supplied
by way of the storage unit to the arrangement. As soon as a cover is
identified, the production of a book block is triggered, thus ensuring a
relatively fast, time-saving processing sequence. In an alternate
embodiment, the control unit may select one of the identified covers and,
based on this selection, may trigger the production of a book block which
may result in a higher flexibility during the production of the printed
products and a better utilization of the printing presses.

[0015]The control system for this arrangement in particular is a so-called
"workflow system," in which the storage unit functions as the control
element that triggers the production of the book block. The storage unit
in this case has a capacity that may be adapted to the workflow system,
meaning it has a corresponding capacity for holding covers.

[0016]For example, if the length of the processing path between the
respective printing press and the further processing stations amounts to
50 book cycles, then the storage unit may be able to accommodate 50
covers in addition to a safety reserve. The conveying device may ensure
that a book block produced as a result of a cover located inside the
storage unit is supplied on time to the further processing from the
capacity of the storage unit.

[0017]It may not be necessary for the conveying device to be fed
information regarding the pre-processing and the post-processing
operations. Rather, for taking over a book block, it may be sufficient if
the conveying device knows at which further processing station the book
block must be deposited. The conveying device may also be fed the
information regarding the latest point in time at which the book block
may reach the destination location. For this, the conveying device may be
provided with a separate intelligence device that regulates the conveying
of the book blocks, sets respective priorities, and may automatically
ensure that a book block reaches the destination on time. The book blocks
may not need to be stored and sequences may not need to be considered.
With an embodiment of the invention in which the covers may be produced
ahead of time, may be stored in the intermediate storage unit, and the
production of corresponding book blocks is then triggered, it may be
possible to have an arrangement or a system where the individual
operating steps may be networked, to be sure, but may selectively be
operated individually through uncoupling of the logic. The storage unit
may be provided with several storage areas from which respectively one
cover can be recalled and supplied to the further processing.

[0018]The covers, which may have very different designs and can be
produced in many different ways, can be intended for softcover books or
also for so-called hardcover books that may be produced either digitally
or conventionally, for example with the aid of offset technology.

[0019]According to one embodiment of the invention, the covers may be
supplied to the storage unit with the aid of a feeder. Alternatively,
they also be supplied with different device.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]The present invention will be more readily understood from the
following detailed description when read in conjunction with the
accompanying drawings, in which:

[0021]FIG. 1 is a schematic view from above of an arrangement according to
the invention; and

[0022]FIG. 2 is a schematic three-dimensional view of the arrangement
according to FIG. 1.

DETAILED DESCRIPTION

[0023]According to FIGS. 1 and 2, the arrangement 1 includes three
printing presses 4 which may be digital printing presses. The paper to be
printed on is respectively supplied to the printing presses 4 by an
unwinding device 3 for unwinding a paper roll 2. However, it is also
possible to connect a printing press, not shown herein, which utilizes
precut individual sheets. The printed-on paper webs may be supplied in a
manner known per se to a folding machine 5, as well as a cutting and
folding device 6. The printed sheets created in this way may be collated
in a collating device 7, so that a book block 8 is finally obtained. If a
single-sheet fed printer is used, it may also be provided with a stacking
device and the collating device 7 may be omitted. The aforementioned
devices as well as the printing presses may be known per se to one
skilled in the art and need not be explained further herein. The number
of printing presses 4 is optional, per se, wherein an arrangement having
only one printing press 4 is also conceivable.

[0024]The arrangement 1 is provided with three cover production devices 12
in which the covers 13 (FIG. 2) may be produced in a manner known per se.
The covers 13 may include, for example, digitally imprinted sheets and
may be embodied as so-called "softcovers" or "hardcovers." The cover
production devices 12 may furthermore comprise a laminating device. A
hard cover may furthermore include different components which are known
to one skilled in the art. A corresponding process for producing hard
covers may furthermore be part of such a cover production device, but
need not be directly connected thereto. As an alternate to being supplied
by the internal cover production devices 12, the covers 13 may also be
supplied from an external source. The manner and production of where the
covers 13 are produced may not be significant. Of course, a series
production that permits supplying the required covers 13 should be
possible.

[0025]The arrangement 1 furthermore comprises three processing devices 19,
19' with respectively one storage unit 16. The storage units 16 may be
drum storage units provided with a wheel 17 that contains several
compartments 18, as disclosed in European patent document EP 1880863 A1.
The covers 13, produced in the cover-producing devices 12, may be
supplied to these storage units 16 with the aid of respectively one
feeder 27. The covers 13 may be moved from the cover-producing devices 12
to the feeders 27, either manually or with the aid of a transporting
device 14 which is indicated with dashed lines herein.

[0026]The storage units 16 and the feeders 27 may form a single module
that may be arranged on or directly in front of the further processing
device 19, 19'. To identify the covers 13 assigned to the respective
storage unit 16, the feeders 27 may be furthermore provided with an
identification device 28 (FIG. 2). The identification device 28 may
comprise a reading device for reading a bar code that may be imprinted on
the respective cover 13. Of course, other identifying elements may also
be used in place of bar codes, such as transponders, magnetic strips or
different types of elements that may store information, wherein a clear
text with numbers or letters may also be detected. If different feeders
may be used in place of the feeders 27 for supplying the covers 13, then
the identification device 28 for identifying the covers 13 may be
arranged on the different feeders.

[0027]The additional processing devices 19 may be respectively provided
with a binding device 20, a cooling tower 21 or another suitable cooling
section, a three-way trimmer 22, as well as a delivery section 23 from
which the finished printed product may be removed. The individual book
blocks 8 may be bound inside binding devices 20 and may be provided with
a cover 13, wherein optional binding methods may be used per se. The book
blocks 8 may be supplied with a conveying device 9 to the binding device
20, either in the direction of the arrows 11 via a side arm of the
conveying device 9 or also in the direction of arrows 10, meaning via the
main conveying flow.

[0028]The conveying device 9 may be provided with several takeover
locations 25, 25' where respectively one book block 8 may be taken over
by the collating device 7, for example, and may then be transported in
the direction of the arrows 10, 11. It may furthermore be provided with
several discharge locations 26 where respectively one book block 8 may be
supplied to a further processing device or processing device 19, 19'. The
conveying device 9 may be realized as a belt conveyor, wherein grippers
or similar elements in principle may also be used for the conveying.

[0029]The controlled conveying device 9, shown in FIGS. 1 and 2 in a
horizontal plane, may also be embodied in all other dimensions and may
convey the book blocks 8 toward the top or toward the bottom. For
example, the conveying device may identify a book block 8 with the aid of
a reading device and may supply it to a further processing device 19,
19', wherein the information relating to the destination may accompany
the book block 8 in the form of a bar code or a data matrix code, or the
information may also be transmitted by a control unit. A book block 8 may
be supplied, for example from the takeover location 25' to the further
processing device 19', which may differs from the other processing
devices 19 in that it comprises an encasing mechanism 24 for encasing the
printed products with a hard cover. The further processing devices 19,
19' may thus be embodied identical or different.

[0030]The arrangement 1 furthermore comprises a control station in the
form of a control unit 15. A control unit 15 of this type may also
comprise a workflow system that receives book data, production
information or process information from a super-imposed system. One
skilled in the art should be familiar with a super-imposed system of this
type in the form of a management information system (abbreviated: MIS).
Of course, data received from a client can also be input manually at the
control station by the operating personnel.

[0031]An embodiment of the method according to the invention may be
explained by the following example: A client or a publisher may place an
order for printed products, for example an order involving 1000 printed
products with 975 different titles. This order may then be assigned to an
existing production unit, or a new production unit may be created. A
production unit may, for example, include a single order, a collection of
orders, or a work shift and may be planned with the aid of the management
information system or may be input accordingly at the workflow system or
the control unit 15.

[0032]The production unit may be pre-sorted with the aid of the MIS, based
on specific criteria, or may be sorted by the workflow system or a
different suitable system. For the exemplary embodiment, a workflow
system in the control station may be responsible for the sorting. A
sorting of this type is useful for grouping the printed products to be
produced according to specified criteria, for example the type of paper,
the folding diagram and the like. With the sorting, the production unit
is defined and is stored in this form for a later processing of the
order.

[0033]In a following step, the workflow system activates the
cover-producing devices 12 to start production of the corresponding
covers 13, wherein the production sequence may be specified in the
production unit. Once the covers are produced, they may be stored
temporarily, for example on pallets, or on a grate or carriage, thus
completing the so-called pre-production process.

[0034]The subsequent feeding of the covers 13 to the storage unit 16 may
take place either automatically or with the aid of a conveying device
arranged between the cover producing device 12 and the storage unit 16,
or a machine operator may deliver the covers 13 to the feeder 27 of a
storage unit 16. The feeder 27 may be provided with a bin, not shown
herein, for accommodating the covers 13. The covers 13 may be separated
in the feeder 27, may be identified with the reading device, and may then
be supplied to the compartments 18 on the storage wheel 17. Each cover 13
may thus be identified and assigned to a storage area. The covers 13 may
be administered by a control unit for the storage unit 16, not shown
herein, or by the binding apparatus 20 that may be connected to the
control unit 15.

[0035]The workflow system may be kept informed continuously of which
covers 13 may be supplied to which compartment of the storage unit 16. As
soon as a cover 13 is known to the workflow system, the system may
trigger the production of a corresponding book block 8 in a suitable
printing press 4. In an alternate embodiment thereto, the control unit 15
may also select one of the identified covers 13 and, based on the
selected cover 13, may trigger the corresponding production of a book
block 8. According to another embodiment, the cover 13 may be provided
with a control code that may be read out or with an identifying feature,
which may trigger the production of a book block 8 on a corresponding
printing press 4 once the identification has been made.

[0036]The book block 8 may then be produced and transferred to the
conveying device 9 at a takeover location 25, 25'. The conveying device 9
may convey the book block 8 to the respective further processing device
19, 19' and may automatically control the time and number of machine
cycles. The condition to be met in this case is that the book block 8 may
be supplied to the further processing device 19, 19' before the storage
unit 16 revolves once. As soon as the book blocks 8 are fed to the
further processing device 19, 19', the associated cover 13 may also be
removed from the storage unit 16.

[0037]The covers 13 stored in the storage units 16 may be called up at any
time, so that the further processing device 19, 19' may be provided
during each operating cycle with a cover 13 from the respective storage
unit 16, regardless of where the respective compartment 18 is located at
the time. Accordingly, the capacity of the storage unit 16 may be
comparatively high. The fact that the storage unit 16 may be arranged on
the respectively used further processing device 19, 19', or directly in
front of this device, means that the covers 13 may have a short conveying
path from the storage unit 16 to the binding device 20, which may clearly
reduce the danger of a malfunction occurring along the conveying path for
the covers 13, meaning after the command for printing the associated book
block 8 is triggered.

[0038]Once the intended cover 13 is combined with the book block 8, the
control unit 15 or the workflow system may be informed that the printed
product has been produced successfully. The workflow system furthermore
may be used to control subsequent processes, such as the further
transport of the printed products to a logistic system and the shipping.

[0039]It will be understood that the above description of the present
invention is susceptible to various modifications, changes and
adaptations, and that the same are intended to be comprehended within the
meaning and range of equivalents of the appended claims.